Furnace top integral lifting device for boiler capacity expansion transformation and using method of furnace top integral lifting device

Abstract

The invention relates to the technical field of boiler transformation construction, and discloses a boiler expansion transformation furnace top integral lifting device and a using method, the boiler expansion transformation furnace top integral lifting device comprises a boiler stand column, a boiler stand column cut-off position is arranged on the boiler stand column, and a furnace top steel beam is arranged above the boiler stand column cut-off position; portal frame supports are fixedly welded to the outer sides of the boiler stand columns located below the cut-off positions of the boiler stand columns, portal frame stand columns are fixedly connected to the upper portions of the portal frame supports, and portal frame top cross beams are fixedly connected to the top ends of the portal frame stand columns; an electric hoist is hung on a top cross beam of the portal frame, and the hoisting end of the electric hoist extends downwards and is connected with the furnace top steel beam. In the lifting process, segmented operation is carried out according to synchronous lifting reference points on portal frame stand columns, synchronous lifting and single table fine adjustment are carried out through a control box, eccentric stress is balanced, the vertical displacement deviation of overall lifting is controlled within a safety threshold value, and the horizontal state of the furnace top in the overall lifting process is maintained.

Description

Technical Field

[0001] This invention relates to the field of boiler renovation and construction technology, specifically to a boiler expansion and renovation furnace top overall lifting device and its usage method. Background Technology

[0002] In existing expansion and renovation projects of old boilers, it is usually necessary to increase the heating surface, which requires physically raising the elevation of the boiler top. Conventional construction techniques generally employ a method of dismantling components and reassembling them on the ground or at height, relying on large crawler cranes or truck cranes for traction power. However, within existing industrial plant areas, the ground space around the boiler has fixed physical boundaries, and the available surface area limits the deployment nodes of large lifting machinery and the operating swing radius of the lifting boom, making it impossible for conventional ground lifting equipment to access the designated working location.

[0003] Meanwhile, conventional component dismantling processes require cutting the original steel structure's connection nodes at high altitudes and then reassembling, welding, and weld inspection at the new elevation. These physical cutting and re-welding processes cause physical damage and peeling of the original anti-corrosion and insulation materials, increasing the amount of on-site repair work. Furthermore, the number of high-altitude dismantling and assembly processes directly increases the overall construction cycle time.

[0004] Furthermore, the physical components of the boiler roof include large plate beams and heavy pressure-bearing components of the steam drum. The overall mass is large and the spatial mass distribution is uneven, with the center of gravity biased towards the side where the steam drum is located. When using conventional uniform traction hoisting methods to lift combined components with eccentric load characteristics, some lifting points with concentrated stress are prone to exceeding the rated tensile force limit of the lifting equipment. At the same time, the uneven load between different lifting points will cause vertical displacement differences, resulting in the lifted boiler roof tilting at a horizontal angle in space. When the internal stress generated by the tilt angle exceeds the allowable deformation threshold of the original frame steel structure, there is a technical defect that the boiler roof frame may twist or the entire load-bearing system may become unstable.

[0005] Therefore, the purpose of this invention is to provide a boiler expansion and renovation furnace top overall lifting device and its usage method to solve the shortcomings of the prior art. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a boiler expansion and renovation furnace top overall lifting device and its usage method, which solves the problems of limited ground physical space in boiler expansion and renovation operations, which prevents the deployment of large hoisting machinery, and the large total mass of the furnace top to be lifted and the offset center of gravity, which cause local overload and vertical displacement deviation during the overall lifting process.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a boiler expansion and renovation furnace top overall lifting device, comprising a boiler column, a boiler column cut-off point provided on the boiler column, and a furnace top steel beam provided above the boiler column cut-off point; a gantry frame support is welded and fixed to the outside of the boiler column below the boiler column cut-off point, a gantry frame column is fixedly connected above the gantry frame support, and a gantry frame top crossbeam is fixedly connected to the top of the gantry frame column; an electric hoist is suspended on the gantry frame top crossbeam, and the lifting end of the electric hoist extends downward and connects to the furnace top steel beam.

[0008] Preferably, the gantry column is composed of multiple seamless steel pipes, the top beam of the gantry is composed of multiple seamless steel pipes, and the gantry columns and the top beam of the gantry are connected by seamless steel pipes with top tie rods.

[0009] Preferably, there are multiple electric hoists, some of which serve as main lifting point electric hoists and others as auxiliary lifting point electric hoists. The auxiliary lifting point electric hoists are centrally arranged in front of and behind the steam drum on the unbalanced side of the top steel beam of the furnace.

[0010] Preferably, the multiple electric hoists are electrically connected to a control box, which is equipped with a self-holding control module for synchronously lifting the multiple electric hoists and an independent operation module for controlling the independent operation of a single electric hoist.

[0011] Preferably, the gantry column is marked with synchronous lifting reference points at predetermined intervals along the vertical direction.

[0012] Preferably, lifting lugs are welded onto the steel beam at the top of the furnace, and the electric hoist is connected to the lifting lugs via shackles and wire ropes; the lifting ends of some adjacent electric hoists are connected as one unit by pulley blocks and wire ropes.

[0013] Preferably, the lifting lug is a welded component made of steel plate, and the lifting lug is arranged on the large plate beam of the furnace top to be lifted and the support beam of the steam drum.

[0014] Preferably, guy ropes are connected in multiple directions on the top crossbeam of the gantry frame, and the other end of the guy rope is fixed obliquely outward.

[0015] Preferably, the lower part of the gantry support is provided with a herringbone diagonal brace.

[0016] A method for using a boiler expansion and retrofitting system with an integral lifting device for the boiler top includes the following steps:

[0017] A gantry support is welded to the outside of the boiler column, and a gantry column and a top beam of the gantry are built on the gantry support. Multiple electric hoists are suspended on the top beam of the gantry.

[0018] At the cut-off point of the boiler column, the top structure of the furnace is cut off and separated from the lower column. The electric hoist is connected to the steel beam at the top of the furnace. The operating system lifts the furnace top as a whole to the first preset distance and then suspends it to perform a stress check.

[0019] According to the synchronous lifting reference point on the gantry column, the furnace top is lifted segment by segment. The operation is stopped at each node and the height deviation of each lifting point is checked. If there is a deviation, the local lifting is finely adjusted by independently controlling a single electric hoist. When each lifting point is restored to horizontal balance, the synchronous lifting operation is continued.

[0020] Repeat step three until the top steel beam of the furnace reaches the designated height. Use steel wire ropes to fix the lifting point to the top crossbeam of the gantry frame and suspend it. Splice and weld the new column and crossbeam at the cut-off point of the boiler column. After inspection and approval, remove the lifting device.

[0021] This invention provides a boiler roof lifting device and its usage method for boiler capacity expansion and renovation. It has the following beneficial effects:

[0022] 1. This invention solves the physical limitation of limited space on site for arranging large lifting machinery by fixing gantry support to the outside of the original boiler column and building gantry column and top beam of gantry. The electric hoist is connected to the steel beam at the top of the furnace, and the boiler column is lifted as a whole at the cut point. This invention transforms the operation of disassembling and assembling parts one by one into the operation of lifting as a whole, reducing the number of processes of disassembling, reassembling and re-welding high-altitude parts.

[0023] 2. This invention uses multiple electric hoists for distributed hoisting, with auxiliary hoists concentrated in front of and behind the steam drum on the unbalanced side of the top steel beam of the furnace. The asymmetrical power arrangement structure redistributes the eccentric load, ensuring that the tensile load borne by each electric hoist involved in the hoisting remains within the rated load range, preventing overload deformation of local nodes.

[0024] 3. This invention employs a self-holding control module and an independent operation module in the control operation box, in conjunction with synchronous lifting reference points marked at preset intervals on the gantry column, to execute segmented successive lifting and height difference monitoring steps. When multiple lifting devices generate vertical displacement deviations, the independent operation module performs local height correction actions on a single electric hoist, controlling the horizontal height difference of each node on the furnace top within the allowable deformation deviation threshold of the mechanical structure, thus maintaining the horizontal state of the furnace top throughout the entire lifting process. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the left and right side columns of the present invention;

[0026] Figure 2 This is a schematic diagram of the top structure of the present invention;

[0027] Figure 3 This is a schematic diagram of the load arrangement at the lifting points of the present invention;

[0028] Figure 4 This is a schematic diagram of the lifting and hoisting points of the present invention.

[0029] Among them, 1. Gantry support; 2. Boiler column; 3. Cut-off point of boiler column; 4. Seamless steel pipe of gantry column; 5. Seamless steel pipe of top tie rod; 6. Seamless steel pipe of top beam of gantry; 7. Gantry column; 8. Top beam of gantry; 9. Steel beam of furnace top; 10. Electric hoist. Detailed Implementation

[0030] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Please see the appendix Figure 1 -Appendix Figure 4 This invention provides a boiler expansion and modification furnace top overall lifting device, including a boiler column 2, a boiler column cut-off point 3 on the boiler column 2, and a furnace top steel beam 9 above the boiler column cut-off point 3; a gantry frame support 1 is welded and fixed to the outside of the boiler column 2 below the boiler column cut-off point 3, a gantry frame column 7 is fixedly connected above the gantry frame support 1, and a gantry frame top crossbeam 8 is fixedly connected to the top of the gantry frame column 7; an electric hoist 10 is suspended on the gantry frame top crossbeam 8, and the lifting end of the electric hoist 10 extends downward and connects to the furnace top steel beam 9;

[0032] Specifically, this device utilizes the existing boiler column 2 as a load-bearing foundation. The physical structure includes the boiler column 2, with a boiler column cut-off point 3 on the boiler column 2. A furnace top steel beam 9 is installed above the boiler column cut-off point 3. A gantry support 1 made of 18mm thick steel plate is fixed to the outside of the boiler column 2 below the boiler column cut-off point 3 by full welding. A gantry column 7 is vertically fixed above the gantry support 1. A gantry top beam 8 is horizontally fixed to the top of the gantry column 7. An electric hoist 10 is suspended on the gantry top beam 8. The lifting end of the electric hoist 10 extends downward and is physically connected to the furnace top steel beam 9. The aforementioned structure avoids the need to erect load-bearing scaffolding starting from the ground, realizing the overall suspension of the furnace top components and providing the foundation for raising it 5 meters upward.

[0033] See appendix Figure 2 The gantry column 7 is composed of multiple seamless steel pipes 4, and the top beam 8 of the gantry is composed of multiple seamless steel pipes 6. The gantry columns 7 and the top beam 8 of the gantry are connected by top tie rods 5.

[0034] Specifically, the gantry column 7 is composed of 10 seamless steel pipes 4 with an outer diameter of 325mm and a wall thickness of 9mm. The top beam 8 of the gantry is composed of multiple seamless steel pipes 6 with an outer diameter of 325mm and a wall thickness of 9mm. The gantry columns 7 and the top beam 8 are cross-connected by seamless steel pipes 5 with an outer diameter of 159mm and a wall thickness of 5mm. The aforementioned material and dimensional settings ensure that the calculated compressive stress on the column with the greatest stress is 30.6MPa, which is lower than the allowable stress of 170MPa for seamless steel pipes, thus meeting the structural load-bearing requirements.

[0035] There are multiple electric hoists 10. Some electric hoists 10 serve as main lifting point electric hoists 10, while others serve as auxiliary lifting point electric hoists 10. The auxiliary lifting point electric hoists 10 are concentrated in front of and behind the steam drum on the heavier side of the steel beam 9 at the top of the furnace.

[0036] Specifically, 12 electric hoists (10) are configured, each with a rated lifting load of 10t. Some of the electric hoists (10) serve as main lifting point hoists (10), while others serve as auxiliary lifting point hoists (10). The auxiliary lifting point hoists (10) are concentrated on the unbalanced side of the steel beam 9 at the top of the furnace, directly in front of and behind the steam drum. This asymmetrical arrangement redistributes the eccentric load, ensuring that the maximum traction force borne by each electric hoist (10) remains within the safe range of 10t.

[0037] See appendix Figure 3Multiple electric hoists 10 are electrically connected to a control box. The control box is equipped with a self-holding control module that controls the synchronous lifting of multiple electric hoists 10 and an independent operation module that controls the independent operation of a single electric hoist 10.

[0038] Specifically, multiple electric hoists 10 are electrically connected to a control box. The control box is equipped with a self-holding control module for synchronous lifting of multiple electric hoists 10 and an independent operation module for independent operation of a single electric hoist 10. The operator outputs commands through the self-holding control module to achieve overall synchronous lifting at a rate of 90mm / min, and performs local height correction actions on a single electric hoist 10 that has displacement deviation through the independent operation module.

[0039] See appendix Figure 4 Synchronous lifting reference points are marked at predetermined intervals along the vertical direction on the gantry column 7;

[0040] Specifically, yellow synchronous lifting reference points are pre-marked at 500mm intervals along the vertical direction on the gantry column 7. Operators compare the height of each lifting point relative to the synchronous lifting reference points to obtain the vertical displacement deviation value of each lifting point, providing the data input source for adjustment commands.

[0041] Lifting lugs are welded onto the steel beam 9 at the top of the furnace. Electric hoists 10 are connected to the lifting lugs via shackles and wire ropes. The lifting ends of some adjacent electric hoists 10 are connected as one unit by pulley blocks and wire ropes.

[0042] Specifically, lifting lugs are welded onto the steel beam 9 at the top of the furnace. Electric hoists 10 are connected to the lifting lugs via shackles of 10t or 16t specifications and steel wire ropes of 28mm diameter. The lifting ends of some adjacent electric hoists 10 are connected as one unit by pulley blocks and steel wire ropes. The integrated steel wire rope configuration allows for automatic and even distribution of physical tension between connected lifting points.

[0043] The lifting lugs are welded components made of steel plates, and they are arranged on the large plate beam of the furnace top to be lifted and the support beam of the steam drum.

[0044] Specifically, the lifting lugs are fully welded components made of 25mm thick steel plates, and are arranged on the large plate beam of the furnace top to be lifted and the support beam of the steam drum. The 25mm thick steel plate material ensures that the connection nodes can withstand a maximum distributed force of 15.8t at a single point.

[0045] Guy ropes are connected in multiple directions on the top beam 8 of the gantry frame, and the other end of the guy ropes is fixed obliquely to the outside.

[0046] Specifically, guy ropes made of 20mm diameter steel wire are connected to the top beam 8 of the gantry in all four directions (north, south, east, and west), with the other end of each guy rope fixed diagonally outward. These guy ropes generate a reverse tension, restricting horizontal displacement of the top beam 8 of the gantry.

[0047] A herringbone brace is installed at the lower part of the gantry support 1;

[0048] Specifically, a herringbone brace is installed at the lower part of the gantry support 1. The herringbone brace converts the vertical downward gravity force on the gantry support 1 into a lateral thrust, which is then distributed and transmitted to the side wall of the boiler column 2.

[0049] A method for using a boiler expansion and retrofitting system with an integral lifting device for the boiler top includes the following steps:

[0050] A gantry support 1 is welded to the outside of the boiler column 2, and a gantry column 7 and a top beam 8 of the gantry are built on the gantry support 1. Multiple electric hoists 10 are suspended on the top beam 8 of the gantry.

[0051] At the boiler column cutting point 3, the furnace top structure is cut off from the lower column and separated. The electric hoist 10 is connected to the furnace top steel beam 9. The operating system lifts the furnace top as a whole to the first preset distance and then stops it to perform a stress check.

[0052] According to the synchronous lifting reference point on the gantry column 7, the furnace top is lifted segment by segment. The operation is stopped at each node and the height deviation of each lifting point is checked. If there is a deviation, the local lifting is finely adjusted by independently controlling a single electric hoist 10. When each lifting point is restored to horizontal balance, the synchronous lifting operation is continued.

[0053] Repeat step three until the top steel beam 9 of the furnace reaches the designated height. Use steel wire ropes to fix the lifting point to the top crossbeam 8 of the gantry frame and suspend it. Splice and weld the newly added column and crossbeam at the cut-off point 3 of the boiler column. After inspection and approval, remove the lifting device.

[0054] Working principle: During the system construction phase, a gantry support 1 is welded to the outside of the boiler column 2, and a herringbone diagonal support is set at the bottom of the gantry support 1; a gantry column 7 composed of multiple seamless steel pipes 4 is fixed above the gantry support 1, and a gantry top beam 8 composed of multiple seamless steel pipes 6 is fixed at the top of the gantry column 7. The gantry columns 7 and the gantry top beam 8 are connected by a top tie rod seamless steel pipe 5, and guy ropes that are fixed diagonally outward are connected in multiple directions to the gantry top beam 8.

[0055] During the power distribution phase, multiple electric hoists 10 are suspended on the top crossbeam 8 of the gantry frame. Some of the electric hoists 10 serve as main lifting point electric hoists 10, while others serve as auxiliary lifting point electric hoists 10. The auxiliary lifting point electric hoists 10 are concentrated on the front and rear of the steam drum on the heavier side of the top steel beam 9 of the furnace. Lifting lugs made of steel plates are welded onto the large plate beam and steam drum support beam of the top steel beam 9 of the furnace.

[0056] During the cutting and trial lifting stage, the furnace top structure is cut off from the lower boiler column 2 at the boiler column cutting point 3. The lifting end of the electric hoist 10 extends downward and is connected to the lifting lug through shackles and wire ropes. The lifting ends of some adjacent electric hoists 10 are connected as one unit through pulley blocks and wire ropes to distribute the load. The control box controls multiple electric hoists 10 to lift the furnace top steel beam 9 by 100mm and then suspend it to check the stress at each lifting point.

[0057] During the segmented synchronous lifting and fine-tuning stage, synchronous lifting reference points are marked every 500mm along the vertical direction on the gantry column 7. The control box drives multiple electric hoists 10 to synchronously lift the furnace top steel beam 9 segment by segment through the self-holding control module. The operation stops when each synchronous lifting reference point is reached, and the height deviation of each lifting point is checked. If a height deviation exists, the control box controls a single electric hoist 10 to perform local lifting and fine-tuning through the independent operation module. When each lifting point is restored to horizontal balance, the synchronous lifting operation continues.

[0058] During the in-situ locking and splicing stage, repeat the above lifting and fine-tuning steps until the top steel beam 9 of the furnace reaches the designated height. Use steel wire ropes to fix the lifting point to the top crossbeam 8 of the gantry frame and suspend it. Splice and weld the newly added column and crossbeam at the cut-off point 3 of the boiler column. After inspection and approval, remove the lifting device to complete the load transfer and height lifting operation.

Claims

1. A boiler expansion and renovation device with an integral lifting mechanism for the furnace top, characterized in that, The system includes a boiler column (2), on which a boiler column cut-off point (3) is provided, and a furnace top steel beam (9) is provided above the boiler column cut-off point (3); a gantry support (1) is welded and fixed to the outside of the boiler column (2) located below the boiler column cut-off point (3), and a gantry column (7) is fixedly connected above the gantry support (1), and a gantry top beam (8) is fixedly connected to the top of the gantry column (7); an electric hoist (10) is suspended on the gantry top beam (8), and the lifting end of the electric hoist (10) extends downward and connects to the furnace top steel beam (9).

2. The boiler expansion and renovation furnace top integral lifting device according to claim 1, characterized in that, The gantry column (7) is composed of multiple seamless steel pipes (4) of the gantry column, and the top beam (8) of the gantry is composed of multiple seamless steel pipes (6) of the top beam of the gantry. The gantry columns (7) and the top beam (8) of the gantry are connected by top tie rod seamless steel pipes (5).

3. The boiler expansion and renovation furnace top integral lifting device according to claim 1, characterized in that, There are multiple electric hoists (10), some of which are used as main hoists (10) and some of which are used as auxiliary hoists (10). The auxiliary hoists (10) are concentrated in front of and behind the steam drum on the bias side of the top steel beam (9) of the furnace.

4. The boiler expansion and renovation furnace top integral lifting device according to claim 3, characterized in that, Multiple electric hoists (10) are electrically connected to a control box. The control box is equipped with a self-holding control module that controls the synchronous lifting of multiple electric hoists (10) and an independent operation module that controls the independent operation of a single electric hoist (10).

5. The boiler expansion and renovation furnace top integral lifting device according to claim 1, characterized in that, The gantry column (7) has synchronous lifting reference points marked at predetermined intervals along the vertical direction.

6. The boiler expansion and renovation furnace top integral lifting device according to claim 1, characterized in that, The top steel beam (9) of the furnace is welded with lifting lugs, and the electric hoist (10) is connected to the lifting lugs by shackles and wire ropes; the lifting ends of some adjacent electric hoists (10) are connected as one unit by pulley blocks and wire ropes.

7. The boiler expansion and renovation furnace top integral lifting device according to claim 6, characterized in that, The lifting lugs are welded components made of steel plates, and they are arranged on the large plate beam of the furnace top to be lifted and the support beam of the steam drum.

8. The boiler expansion and renovation furnace top integral lifting device according to claim 1, characterized in that, Guy ropes are connected in multiple directions on the top beam (8) of the gantry frame, and the other end of the guy rope is fixed obliquely to the outside.

9. A boiler expansion and renovation furnace top integral lifting device according to claim 1, characterized in that, The lower part of the gantry support (1) is provided with a herringbone diagonal support.

10. A method of using a boiler expansion and renovation furnace top integral lifting device, applied to the boiler expansion and renovation furnace top integral lifting device according to any one of claims 1-9, characterized in that, Includes the following steps: A gantry support (1) is welded to the outside of the boiler column (2), and a gantry column (7) and a top beam (8) of the gantry are built on the gantry support (1). Multiple electric hoists (10) are suspended on the top beam (8). At the boiler column cutting point (3), the furnace top structure is cut off from the lower column, and the electric hoist (10) is connected to the furnace top steel beam (9). The operating system lifts the furnace top as a whole by the first preset distance and then stops it to perform a stress check. According to the synchronous lifting reference point on the gantry column (7), the furnace top is lifted segment by segment. The operation is stopped when each node is lifted and the height deviation of each lifting point is checked. If there is a deviation, the local lifting and fine adjustment is made by independently controlling a single electric hoist (10). When each lifting point is restored to horizontal balance, the synchronous lifting operation is continued. Repeat step three until the top steel beam (9) of the furnace reaches the specified height. Use steel wire rope to fix the lifting point on the top crossbeam (8) of the gantry frame and suspend it. Splice and weld the new column and crossbeam at the cut-off point (3) of the boiler column. After inspection and approval, remove the lifting device.

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